Radio-frequency sealable polymer and articles thereof

Abstract

The present invention relates to a reactor-grade copolyester composition having radio-frequency sealing capability. The present invention further relates to films and thermoformable packaging prepared from the reactor-grade copolyester composition and the methods for making such films and articles therefrom.

What is claimed is: 
     
         1 . A method for making an article of manufacture comprising:
 thermoforming a film into a shape having first and second edges, placing said first and second edges in an overlapping position and, sealing said first and second edges together by subjecting the overlapping edges to an RF-sealing energy, said film comprising a reactor grade copolyester comprising:
 (A) an acid residue moiety comprising:
 (1) greater than about 70 mole % terephthalic acid; and 
 (2) from about 0 to 30 mole % of a modifying acid selected from the group consisting of isophthalic acid, adipic acid, azelaic acid, succinic acid, naphthalenedicarboxylic acid, cyclohexanedicarboxylic acid, and mixtures thereof, and 
 
 (B) a diol residue moiety comprising,
 (1) from about 88 to about 94 mole % ethylene glycol; and 
 (2) from about 6 to about 12 mole % of a modifying diol selected from the group consisting of 1,4-cyclohexanedimethanol, diethylene glycol, neopentyl glycol, 2,2,4,4-tetramethylcyclobutane-1,3-diol, isosorbide and mixtures thereof, 
 
   wherein the copolyester has a crystallinity defined by a minimum crystallization half time (t 1/2 min ) of from at least 1.5 to 30 minutes and wherein the sum of the mole percentages of component (A) are based on 100 mole percent of the acid residue moiety and the sum of the mole percentages of component (B) are based on 100 mole percent of the diol residue moiety.   
     
     
         2 . The method of  claim 1  wherein said acid residue moiety is greater than about 80 mole % terephthalic acid. 
     
     
         3 . The method of  claim 1  wherein said acid residue moiety is greater than about 90 mole % terephthalic acid. 
     
     
         4 . The method of  claim 1  wherein said modifying diol residue is 1,4-cyclohexanedimethanol. 
     
     
         5 . The method of  claim 1  wherein the film thickness is 1 to 100 mils. 
     
     
         6 . The method of  claim 5  wherein the film thickness is 5 to 30 mils. 
     
     
         7 . The method of  claim 1  wherein said article is selected from the group consisting of bags, containers, packages, automotive interior trim fabrics, flotation devices, tarps, tent coverings, medical collection bags, medical ostomy bags, medical infusion or intravenous bags, air mattresses, toys, food packaging, retail product blister packaging, and tubing. 
     
     
         8 . The method of  claim 1  wherein the film is a monolayer structure. 
     
     
         9 . The method of  claim 1  wherein the film is a multi-layer structure. 
     
     
         10 . The method of  claim 1 , further comprising blending:
 (A) from 25 to 75 weight percent of the copolyester of  claim 1 , and   (B) from 25 to 75 weight percent of post-consumer recycle stream.   
     
     
         11 . The method of  claim 10  wherein the blend has a crystallinity defined by a minimum crystallization half time (t 1/2 min ) of from at least 1.5 to 30 minutes. 
     
     
         12 . The method of  claim 10  wherein said acid residue moiety is greater than about 80 mole % terephthalic acid. 
     
     
         13 . The method of  claim 10  wherein said acid residue moiety is greater than about 90 mole % terephthalic acid. 
     
     
         14 . The method of  claim 10  wherein said modifying diol residue is 1,4-cyclohexanedimethanol. 
     
     
         15 . The method of  claim 10  wherein the film thickness is 1 to 100 mils. 
     
     
         16 . The method of  claim 15  wherein the film thickness is 5 to 30 mils. 
     
     
         17 . The method of  claim 10  wherein said article is selected from the group consisting of bags, containers, packages, automotive interior trim fabrics, flotation devices, tarps, tent coverings, medical collection bags, medical ostomy bags, medical infusion or intravenous bags, air mattresses, toys, food packaging, retail product blister packaging, and tubing. 
     
     
         18 . The method of  claim 10  wherein the film is a monolayer structure. 
     
     
         19 . The method of  claim 10  wherein the film is a multi-layer structure.